Compound metal body and process of making same.



J. F. MONNOT.

coMPoUND METAL BODY AND PROCESS or MAKING SAME.

APPLICATION FILED NOV. 26, 1907. RBNBWED JUNE 16, 1909.

Patented Jan. 25, 1910.

i lnven tor:

TATE@ PATENT @FFCE JOHN FERREOL MONNOT, OF NEW YORK, N. Y., ASSIGNOR T0 DUPLEX METALS COM- PANY, OF NEWIYORK, N. Y., A, CORPORATION OF NEW YORK.

COMPGUNID METALBODY AND PROCESS 0F MAKING SAME.

Application llledl November 28, 1807, Serial No. 403,881.

To all whom it 'may concern:

Be it known that I, JOHN FERREOL MoN- No'r, a citizen of the United States, residing at New York in the county of New York and State of ew York, have invented certain new and useful Compound Metal Bodies and Processes of Making Same; and I do Ahereby declare the following to be a full,

process for producing clad metals, by which term is meant bodies comprising a core or base of one metal, (iron or steel for instance) havin united thereto and preferably inseparab y united or welded thereto, a substantial coating of an unlike metal, (for instance, copper, silver, gold, aluminum, brass, bronze, aluminum bronze, etc); and to the clad metals produced thereby.

in Patents Nos. 851,684, 851,993 and 858,716, and in various pending applications, including particularly applications Sr. Nos.

, 281,680, led (lctober 6, 1905, 891,673 filed September 6, i907 and 400,843 filed November '5, 1907, I have illustrated and described apparatus and processes for producing clad metal bodies such as referred to, and comprising various pairs of unlike metals such as referred to inseparably Welded together, the pairs of metals being in some cases united by an intermediate-thin layer of a third metal inseparably Welded to both.

The process set forth in my Patent No. 853,716 and in various of my applications,

' isbased upon the discovery by me that when `a clean metallic surface of one metal 1ron or steel for example) is contacted momentarily with a molten body of an unlike metal (copper for example) maintained at a temperature far above the melting and ordinary casting temperatures, and in what appears to be an lactive condition to which, in said patent, I have applied the term supermolten condition, the said supermolten metal will unite to the first metal by a union .equivalent to and probably constituting a truey weld union, the metals so joined being inse arable, after the molten metal has solidi ed and cooled, by any mere strippingx Specication of Letters Patent.

Patented Jan. 25, i910. Renewed June 16, 1009. Serial No. 502,445.

action such as may be exerted by means of a cold chisel or by changes of temperature or othertreatment which usually sulices to separate metals Which are merely adherent and not coherent to each other.

It is well known that in order to obtain high electrical conductivity in highly conductive metals, such as copper, silver and the like, extreme urity'oi the said metal is necessary; a small) fraction of one per cent. of impurity in copper reducing the conductivlty of the copper enormously. While there is no particular difficulty in casting copper in the ordinary manner, and at ordinary casting temperatures, into molds, even into iron molds and obtaining thereby ingots substantially as pure as was the metal when cast, it is found extremely diflicult to maintain high purity of super-molten copper united to iron or steel by the processes oi' my said former applications; the superniolten copper appearing to have an action, solvent or otherwise, on the iron or steel, which is lacking with copper at the ordinary casting temperature and which results in the penetration of traces of iron a considerable distance into the supermolten copper; such penetration occurring even when the copper mass in supermolten condition is in contact with the iron or steel for a few seconds only. The object of the present invention is to overcome this difiiculty and to produce ingots, bars, Wires, etc., the main ortion of which is uncontaminated by meta from the coreor base to which the cast metal is united.

According to the process herein described, a coating of substantially uncontaminated metal, copper for instance, is applied to an iron or steel base or core, in the following manner: A suitable mold such as is coinmonly used in makin copper ingots of the desired size, is provided with a collapsible yand removable core, and molten copper of the desired degree Iof purity is cast into the annular space between this core and the sides of the mold, such casting being done at ordinary casting temperature so that there may be no action of the molten copper upon the said core or upon the sides 'of the mold if, (as is permissible) such mold be of iron. Meanwhile, a core or base of metal to be coated (steel for example) has applied to it by processes such as set forth 1n Amy said Patent No.l 853,716 or my said a plication Sr. No. 400,843 filed Nov. 5, 190 or any los other process by which absolute unionwcan be assured, a coating of suitable metal,

` usually the same as that of the 'main coatv ject and its coating being o such diameter therein ready for the pourin that there remains between the coating and the cast annulus in the mold, a slight space into which molten -metal may be poured. Molten metal, usually the saine metal as that from which the said annulus was cast, is then poured into this annular space. When this last body of metal solidifies it unites the cast annilus and the coating of the object within the Vannulus, so uniting all into one unitary mass. rEhe metal is then' compacted by workin in the usual manner., that is to say, by ro ling, dies or the like.v y proceeding ,in'this manner contact of the suerinolten metal with the unlike metal of t e base' is avoided in 'forming the inain body ofthe coating, and

therefore there can be no contamination of the main portion at least of the coating as it finally exists,'with metal from this base.

The accompanying drawings` illustrate more or less diagrammatically, the carrying out of my said process /and show apparatus such as may be usedsin carrying it out.

In said drawings: Figure 1 shows a central vertical section of a mold such as may be used for casting the said ann'ulus and a collapsible core within it; Fig. 2 shows a top View of the same parts, the core being in place; Fig. .3 shows a central vertical section of the mold and cast annulus after the collapsible core has been withdrawn; Fig. 4 shows a section 'of the said mold and annulus with the thinly coated base in place of the molten metal to-unite such base an annulus; and

Fig. 5 shows a central vertical section of the thinl coated base as prepared for insertion within the said cast annulus. Fig. 6 shows a transverse section of an ingot such as reduced by the process herein described.

n the drawings, 1 desi ates a mold such as may be used for forming pure eoper ingots, and 2 designates a collapsible'eore coni- 'prising ya plurality of sections of ta ering erm which may be removed separate the mold and the core as a whole having no draft. Into this mold molten coating metal of the desired `purity is cast to form a'n an- "nulus 3. The sections of the core 2 are then withdrawn.. Meanwhile, a billet 4 of steel or other metal forming the-base has a thin coating formed on it by aY recess which will unite the metal of such tin coatin4 firmly to the said base 4, suchmetal of t e thin coating being usually the same metal as'that certain cases, as hereinafter explained, 'it Amay ressing, drawing throughvab e refractory material,

ducts 8 directed toward the annl'ar space 6.

the annulus 3 is-formed; though in aaneen be a diii'erent metal In this particular in-` i stance it will be assumed that. the metal of such thin coating is copper. /Said ythin coating may be formed on base i4 by merely dipping the base momentarily insuperinolten copper and vthen withdrawing the base under' conditions precluding oxidation, or a somewhat thicker coating may be ,'formed by segregating a thin layer of the superinolten metal by the inetlwdtdescribed in my said Patent No. 853,716,forby first film coating the base. by momentary` contact with superniolten coating metal ,and then coat-ing coatin upon such film coating by the nietlio` set forth in my said application filed November 5, i907 sr. No; 400,843. While,-

the annulus 3 is still very hot, and While the base 4 and theicoating `5 formed thereon asV just described, are also still very hot, said coated base is inserted within the annulus, and molten metal, usually the same metal as a Vthicker that of which vthe annulus isformed, `is d poured into the annular space 6 (Fig. 4) beV tween said base and ,the annuliis 3. This 'metal last poured need not be superniolten as it will unite readily at ordinary casting temperature to the metal of the annulus 3 an also to the coating of the base 4. It should,

however be quite hot in order that it may be Y 95V highly fluid and may fill thefsaid annular.

space completely; and to avoid washing awa of the metal of the annulus or of the coatingof the base, the molten metal tofill.

this annular space 6 should preferably be poured directly downward. For this purpose means may be used such as indicated in Fi 4, comprising a pouring tile 7, of suitthrough a whieli in o suitable melting oint,

o. 391,673 --and Sr.

aving suitable such w-ipin liquid having theeti'ect o free in the mo tenmetal cast through it from oxid impurities, entrained and occluded gases etc., and also of dissolving off from the surfaces of the annulus and the coated base'A of oxid impurities thereon.; or I any traces mayvprovide the surface of the annulu's and the coating of the base with a roteetive coatin oit suitable material, suc chlori which will be ofthe Vmolten metal. The coated base 4 1S- referably vtransferred from the point where its thin' coating is -applied to it, tothe said as `zine driven 0E by the heat* mold. 1, under conditions precluding oxide:HV

tion'of its surface, for example, its surface may be covered with a fiux-coating such as may be formed by drawing it through a bath iso l layers of compound coating will of molten flux or like metal, as described in my said application filed Nov. 5, 1907 Si'. No. 400,843. or the transfer may be effected in a bell jar such as illustrated in my said Patent No. 853,716 and also indicated more or less diagrammatically in Fig. 5, such bell jar being filled with a non-oxidizing or protective atmosphere (such as producer gas made from charcoal). In Fig. 5 9 designates the said bell jar. lf the thin coating of the billet be ot copper, as assumed, and if the anniilus be of copper, as also assumed, it will be seen that molten copper cast into the annular space (i will imite readily with the highly heated but solid surfaces of copper on both sides, uniting both bodies of copper into one.

ln some cases, for example, when the main portion of the final coating is to be of a metal oft relatively low melting point or containing a readily volatilizable ingredient, for example, when the metal of the main coat-- ing is to be ot brass, the metal of the thin coating toi-ined on the base 4, may be a metal capable ol being heated to a siipeimolten temperature at which it will imite with steel, and with which the brass readily unites, for examplen copper; and in such case the metal poured into the annular space (i may be either molten brass or molten copper. Likewise, if the coating to be formed is to consist mainly of niiliis 3 may be cast from aluminum, the thin coat-ing 5 maybe copper and the metal cast into the annular space 6 may be either molten alnminum.or molten copper.

The product of the process abovedescribed consists', as will be seen, of a core or base of one metal having weld united thereto a coating of an unlike metal, an annulus of' relatively pure metal surrounding said corel and an intermediate layer of niet-al uniting said aniiulus and Weld-coating, all of these various layers oi metal being firmly and inseparably united. lf the aunulus, uniting layer, and the tirst coating of the ingot be all of the saine metal, in general such different layers Will be indistinguishable one from another, except that probably a cross section of' sucha core, properly etched, will u on eX- amination under the microscope disc ose the different layers of metal. But if the intermediate or binding layer be a different metal from the annulus 3 and first coatin of the core, (for example, if said binding layer be of aluminum, the annulus and the first coating of the core being ot copper) the three be clearly distinguished from each other', although the metals will be so united as to be, for racti cal purposes, one integral mass. ig. 6 showsa cross section of a com ound metal object (Wire for example) suc as maybe produced by extending an ingot produced as above described, 4 designates the base, 5 the aluminum, the am first coatin thereof, 3 the main coating or annulus anc 10 the uniting layer.

It will be seen that extremely ductivity of the metal of the annulus 3 and uniting layer 10 may be insured in objects produced as described herein, since the metal of these layers has no o portunity whatever to contact with the metal) of the base ft.

What I claim is 1. 'lhe process of producing compound high connietal ybodies which comprises applying to a body to be coated a protective layer ot an uii like metal, assembling with the oluectl so coated a solid body ot the desired coat-ing metal spaced away trom said object and While both said body and said object to be coated are hot, casting into the space between them a molten body oty metal capable ot uniting with said body of coating metal and the said protective coating of the object to be coated, and permitting the metal so cast to solidify.

The process of producing compound metal bodies which comprises applying to a body to be coated a rotective layer ot' an unlike metal, assemb in conceiitrically with the object to be coate a solid body of the desired coatin metal spaced away from said object and wliile both said body and said object to be coated are hot, casting into the space between them a molten body of metal capable of uniting with said body of coating metal and the said protective coating of the object to be coated,`and permitting the metal so cast to solidify.

3. The rocess of producing compound metal bodies which comprises applying to a body to be coated a welded on protective layer of an unlike metal, assembling with the object so coated a solid body of the desired coatinV metal spaced away from said object and w ile both said body and said object to be coated are hot, castin into the space between them a molten body of metal capable of uniting with said body of coating metal and the said protective coating of the object to be coated, and permitting the metal so cast to solidify.

4. The process of producing compound metal bodies which comprises applying to a bodyl to be coated a welded on protective layer of an unlike metal, assembling concentrically with the object so coated but spaced. away therefrom a solid bod of the desired coatin metal and while botli said body and said o ject to be coated are hot, casting into the slpace between them a molten body of meta 4capable of uniting with said body 01" coating metal-and the said protective ccating of the obiect to be coated, and permitting the metal so cast to solidify.

5. The rocess of producing compound metal bodies which comprises weld coatingv a ferrous metal base with a non-ferrous metal of high melting point, assembling with Gti the base so coated a body of the desired metal of high melting point, assembling with coatin metal of the character desired spaced away rom said base, and while both are hot casting in the space between them a body of molten metal capable of uniting with boththe coating of said base and with thesaid body of coating metal, and permitting the molten metal so cast to solidify. p

6. The rocess of producing compound metal bodies which comprises weld coating a, ferrous metal base with a non-ferrous the base so coated -a body of co per spaced away from said base and while oth are hot casting in the space between them 'a body of molten metal capable .of uniting with both the coating of said base copper body, and ermitting metal so cast to solidify 7. The rocess of` producing compound metal bodies which comprises weld-coating a ferrous metal base by contact with `a lsu ermolten mass of non-ferrous coating meta of molten copper, forming and with said annulus,

high melting point, forming an annulus of the desired coating metal somewhat larger than said weld-coated base and while both said annulus and said coated base are highly heated placing lthe base within said annulus and pouring into the space between its 'coating and the said annulus, a molten metal capable of uniting both with said' coating metal so cast to solidify.

andv with the said the molten` intermediate said wel and permitting the lsurrounding said base and unite 9. The process of Aproducing compound metal bodies which comprises weld-coating a ferrous metal base by contact with a su ermolten mass of non-ferrous coating meta of ,high melting point, forming an annulus ofy the desired coating metal somewhat larger than said vweld-coated base and while both 'said annulus and said coatedbase arehighly heated, placing the base within said annulus f and pouring molten tween its coatin and the said, annulus, through ala er o wiping material, and then permitting t e metal-so cast to solidify.

10. The processfof producing compound metal into the space bemetal bodies which comprises weld coating v a ferrous metal base by contact with superl molten copper, forming an annulus of coper somewhat larger t ase and while both said annulus and the coated base are hot, placing said base in the annulus and casting molten copper into the space between them through a layer of wiping material, and permitting the' metal so cast to solidify.

11. A compound metal body comprisin a ferrous metal base and an annular body o non-ferrous metalsurrounding saidbase and united thereto by a weld-coating of non-ferrous metal on the base and a layer of metal d-coatiiigand annulus and united to both. l

12. A compound metal body comprising a ferrous metal base and a cop er annulus d. thereto by a weld-coating of copper on said base and a layer of copper intermediate said annulus and weld-coating and united to both.

an said weld-coated 'In testimony whereof I ax my signature, y

in the presence of two witnesses.

. JOHN FERREOL MONNOT. Witnesses :v H. M. MARBLE,

P. MoELRor. 

